Repositionable Wire Deck Assemblies for a Storage Rack

ABSTRACT

Storage systems are described comprising wire shelves and brackets, which are configured to increase the storage capacity of a storage rack by utilizing or converting the space between adjacent shelves into additional storage space is provided. In one embodiment, a storage system utilizes a full-width wire rack and a partial-width wire rack to convert a space between a first shelf panel and a second shelf panel on a storage rack into usable storage space. The full-width wire rack comprises a plurality of longitudinal rods, at least one transverse rod interconnected with at least some of the plurality of longitudinal rods, and a plurality of downwardly turned prongs configured to detachably engage a plurality of keyhole-shaped openings in at least one of the first and second vertical support members to detachably connect the full-width wire rack to the storage rack. The partial-width wire rack is suspended from the full-width wire rack by at least one S-shaped bracket.

This application claims priority to a U.S. Patent ProvisionalApplication Nos. 61/804,612 and 61/804,599, both filed on Mar. 22, 2013,the entire contents of which are hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates generally to wire shelves and bracketsconfigured to be detachably connected to a storage rack.

BACKGROUND

Storage racks and shelving units are commonly used to store a variety ofdifferent articles, such as tools and equipment in a garage (e.g.,drills, brooms, shovels, extension cords, etc.), in an organized andreadily accessible manner. Typical storage racks include left and rightend support units and front and rear cross beams extending between theend support units. Together, corresponding front and rear crossbeamsextending between the end support units define a frame configured tosupport a shelf for storing various articles. Typically, each endsupport unit includes front and rear vertical support members and crossbraces, both horizontal and diagonal, interconnecting the front and rearvertical support members.

One common type of storage rack known in the art is a “boltless” rack,in which at least some of the members of the rack are configured to beassembled without the use of permanent mechanical fasteners. In someconventional boltless racks, the members of the end support units arepermanently coupled together, such as by welding or riveting, and thecrossbeams are detachably connected to the vertical support members ofthe end support units. Typically, the vertical support posts include aseries of apertures, such as wedge-shaped slots or keyhole-shapedopenings, configured to detachably receive interconnecting members, suchas rivets or lances, on opposite ends of the cross beams. Accordingly,boltless racks are configured to permit easy assembly and disassembly ofthe storage rack or shelving unit without the use of tools, and topermit compact and economical shipment of the unit. An example of aboltless shelving unit is shown and described in U.S. patent applicationSer. No. 13/360,543, entitled “Modular Rack Assembly,” the entirecontents of which are hereby incorporated by reference.

The storage capacity of conventional storage racks is limited by thenumber of shelves. However, adding additional full length shelves maynot accommodate taller articles stored on the shelves (i.e., tallerarticles may not permit additional full length shelves to be installedbetween two existing adjacent shelves).

One attempt to address this problem is to add a rod attachment to thewire shelves. For example, U.S. Pat. No. 5,405,026 to Lee discloses aclothes hanger rod attachment to be used in combination with wireshelves. In Lee, the hanger rod is connected to the wire shelves viahooks without using a bracket. Yet, Lee's disclosure is limited to usewith clothes hanger rod which is unlikely provide enough storage spacebetween the rod and the wire shelves.

Another approach is to use a suspended shelving system. For example,U.S. Pat. No. 7,798,341 to Richardson discloses a suspended shelvingsystem including a shelving panel supported by a plurality of hangermembers, which are secured to overhead members. However, Richardson'ssuspended shelving system requires that it is secured to an overheadstructure or ceilings. Furthermore, the crossmembers connecting theshelving system to a hanger is rotatable, yet fixed to a distal end ofthe shelving member, which renders less flexibility in locating thesuspended shelving system.

Thus, there is still a need for a storage system, which enables a userto utilize or convert a space between two storage shelves in a storagerack to increase the storage capacity of a storage rack with a minimumuse of tools.

SUMMARY OF THE INVENTION

The present invention is directed to wire shelves and brackets which areconfigured to increase the storage capacity of a storage rack byutilizing or converting the space between adjacent shelves intoadditional storage space, for example, by adding shelves between theadjacent shelves. Additionally, the present invention may utilize one ormore wire shelves which do not span the full width of the storage rack,thereby accommodating taller articles stored on the shelves.

In one embodiment, a storage system is configured to convert a spacebetween a first shelf panel and a second shelf panel on a storage rackinto usable storage space, such as by adding one or more shelves betweenthe first and second shelf panels. The storage rack comprises a firstvertical support member and a second vertical support member. Thestorage rack has a width defined by the distance between the firstvertical member and the second vertical member. The system comprises afull-width wire rack comprising a plurality of longitudinal rods, atleast one transverse rod interconnected with at least some of theplurality of longitudinal rods, and a plurality of downwardly turnedprongs configured to detachably engage a plurality of keyhole-shapedopenings in at least one of the first and second vertical supportmembers to detachably connect the full-width wire rack to the storagerack. The system further comprises a partial-width wire rack suspendedfrom the full-width wire rack by at least one bracket that is preferablyS-shaped although other types of brackets could be used.

In another embodiment, a storage rack comprises first and secondvertical support members each having a plurality of key-hole shapedopenings. In this embodiment, a first wire rack has a plurality oflongitudinal rods, at least one transverse rod interconnected with atleast some of the plurality of longitudinal rods, and at least onedownwardly turned prong configured to detachably engage at least one ofthe plurality of keyhole-shaped openings in the vertical support memberto detachably connect the wire rack to the storage rack. The distancebetween the first and second vertical support members defines a width ofthe rack. The system comprises a second wire rack having a plurality ofinterconnected longitudinal rods and transverse rods and at least onedownwardly turned prong. The system further comprises at least onebracket, preferably S-shaped, having a first hook end and a second hookdisposed at either end, sized and dimensioned to hook at least one ofthe longitudinal rods and transverse rods.

Various objects, features, aspects and advantages of the inventivesubject matter will become more apparent from the following detaileddescription of preferred embodiments, along with the accompanyingdrawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of support bracket according to the present invention aredescribed with reference to the following figures. The same referencenumerals are used throughout the figures to reference like features andcomponents. The figures are not necessarily drawn to scale.

FIG. 1 is a front perspective view of an existing boltless storage rackhaving wire shelves and brackets of the present invention installedthereon;

FIG. 2A is a perspective view of full-width wire shelf according to oneembodiment of the present invention;

FIG. 2B is a perspective view of a partial width wire shelf according toone embodiment of the present invention;

FIG. 2C is a perspective view of a partial width wire shelf according toone embodiment of the present invention; and

FIG. 3 is a perspective view of a hook according to one embodiment ofthe present invention.

DETAILED DESCRIPTION

The following discussion provides many example embodiments of theinventive subject matter. Although each embodiment represents a singlecombination of inventive elements, the inventive subject matter isconsidered to include all possible combinations of the disclosedelements. Thus if one embodiment comprises elements A, B, and C, and asecond embodiment comprises elements B and D, then the inventive subjectmatter is also considered to include other remaining combinations of A,B, C, or D, even if not explicitly disclosed.

The present invention relates generally to wire shelves and bracketsconfigured to be detachably connected to a storage rack. The wireshelves and brackets are configured to increase the storage capacity ofan existing storage rack by utilizing or converting the space betweentwo adjacent shelves on the existing storage rack into additionalorganized storage space. The wire shelves are repositionable along thevertical support posts such that the height of the wire shelves and thespacing between the wire shelves and the existing shelf panels on thestorage rack can be selected to accommodate variously shaped and sizedarticles, such as tools and other equipment commonly stored in a garage.Additionally, the brackets are configured to suspend additional wireshelves from the wire shelf which is coupled to the vertical supportposts of the storage rack.

Referring now to the embodiment illustrated in FIG. 1, a storage rack100 is illustrated having two full-width wire shelves 101 detachablycoupled to the storage rack 100. The storage rack is also illustratedhaving two partial-width wire shelves 102 detachably coupled on one endto the storage rack 100 and suspended on an opposite end from one of thefull-width wire shelves 101 by a plurality of S-shaped brackets 104,although other shaped brackets could be used. Additionally, the storagerack 100 is illustrated having two partial-width wire shelves 103completely suspended from one of the full-width wire shelves 101 by aplurality of S-shaped brackets 104. As used herein, the term “plurality”shall mean two or more.

With continued reference to FIG. 1, the storage rack 100 includes leftand right end support units 105, 106, respectively, interconnected byfront and rear crossbeams 107, 108, respectively. Each end support unit105, 106 includes front and rear vertical support posts 109, 110,respectively, and horizontal braces 111 extending between the front andrear vertical support posts 109, 110 (i.e., front ends 112 of thehorizontal braces 111 are connected to the front vertical support posts109 and rear ends 113 of the horizontal braces 111 are connected to therear vertical support posts 110). In the illustrated embodiment, eachend support unit 105, 106 includes five horizontal braces 111, althoughit will be appreciated that the end support units 105, 106 may have anyother suitable number of horizontal support braces 111, such as betweentwo and ten or more, depending upon the desired storage capacity of thestorage rack 100 and the shape and size of the various articles thestorage rack 100 is configured to support. In another embodiment, theend support units 105, 106 may also include diagonal braces extendingbetween the front and rear vertical support posts 109, 110,respectively. In the illustrated embodiment, the horizontal braces 111are boltlessly and detachably connected to the vertical support posts109, 110, although it will be appreciated that the horizontal braces 111may be connected to the vertical support posts 109, 110 by any othersuitable means, such as mechanical fastening or welding.

With continued reference to FIG. 1, a width can be defined by a distancebetween two front vertical support posts 109. It is also contemplatedthat a width can be defined by a distance between the front verticalpost 109 and the rear vertical support 110. The full-width wire shelf101 has a first width that is substantially similar to the width asdefined. The partial-width wire shelves 102, 103 have a second widththat is shorter than the first width of the full-width wire shelf 101.

With continued reference to FIG. 1, each of the vertical support posts109, 110 is a beam having two generally orthogonal legs 114, 115 (i.e.,each of the vertical support posts 109, 110 includes a front leg 114 anda side leg 115 extending rearward from the front leg 114). Together, thelegs 114, 115 define a beam having an L-shaped transverse cross-section.It will be appreciated, however, that the vertical support posts 114,115 may have any other suitable shape, such as a U-shaped or Z-shapedtransverse cross-section. Additionally, in the illustrated embodiment,each of the legs 114, 115 of the vertical support posts 109, 110includes a plurality of keyhole-shaped openings 116 arranged in acolumn. Each of the keyhole-shaped openings 116 includes a relativelylarger upper circular opening 117 and a relatively smaller elongatedopening 118 extending downward from a lower end of the larger opening117. As described in detail below, contemplated wire shelves 101, 102can be boltlessly and detachably connected to the keyhole openings 116in the vertical support posts 114, 115.

With continued reference to FIG. 1, opposite ends 119, 120 of the frontand rear crossbeams 107, 108 are boltlessly coupled to the front andrear vertical support posts 109, 110, respectively. Together, thecrossbeams 107, 108 and the horizontal braces 111 define a ledge or aframe configured to support at least one shelf panel 121 or other planarsupport member. It will be appreciated that the storage rack 100 mayinclude any suitable number of crossbeams 107, 108, such as between twoand ten or more. Additionally, the crossbeams 107, 108 may be positionedat any suitable elevation along the vertical support posts 109, 110,depending upon the locations of the keyhole-shaped openings 116 in thevertical support posts 109, 110, the desired storage capacity of thestorage rack 100, and/or the shape and size of the various articles thestorage rack 100 is configured to support. In the illustratedembodiment, the number and elevation of the front and rear crossbeams107, 108 corresponds to the number and elevation of the horizontalbraces 111, although it will be appreciated that the number andelevation of the front and rear crossbeams 107, 108 may differ from thehorizontal braces 111. The crossbeams 107, 108 and the horizontal braces111 may have any suitable shape, such as a generally omega-shaped,C-shaped, or Z-shaped transverse cross-section.

With continued reference to FIG. 1, two full-width wire shelves 101 andfour partial width wire shelves 102, 103 are detachably coupled to theboltless storage rack 100. It will be appreciated, however, that anyother suitable number of full-width and partial-width wire shelves 101,102, 103 may be provided, depending upon the desired additional storagecapacity of the storage rack 100 and the shape and size of the articlesthe user desires to store and arrange on the wire shelves 101, 102, 103and the shelf panels 121.

With reference now to FIG. 2A, each of the full-width wire shelves 101includes a plurality of interconnected longitudinal rods 125 andtransverse rods 126. Together, the longitudinal and transverse rods 125,126, respectively, define a mesh wire shelf 101 configured to supportvarious articles, such as tools and other equipment commonly stored in agarage. Additionally, opposite ends of the outermost longitudinal rods125 include downwardly turned prongs 127 (i.e., each of the four cornersof the full-width wire shelf 101 includes a downwardly turned prong127). The downwardly turned prongs 127 are configured to detachablyengage the keyhole-shaped openings 116 in the side legs 115 of thevertical support posts 114, 115 to detachably couple the full-width wireshelf 101 to the storage rack 100, as illustrated in FIG. 1. Thefull-width shelves 101 are configured to extend completely between thevertical support posts 114, 115 of the storage rack 100 such that allfour corners of the full-width wire shelf 101 are supported by thevertical support posts 114, 115.

With reference now to FIG. 2B, the partial-width wire shelf 102 includesa plurality of interconnected longitudinal rods 128 and transverse rods129. Together, the longitudinal and transverse rods 128, 129,respectively, define a mesh wire shelf 102 configured to support variousarticles, such as tools and other equipment commonly stored in a garage.Unlike the full-width wire shelf 101 described above, only one end 130of the partial-width wire shelf 102 is configured to be supported by thevertical support posts 109, 110 of the storage rack 100. The other end131 of the partial-width wire shelf 102 is configured to be suspendedfrom the full-width wire shelf 101 by at least one S-shaped bracket 104.In the illustrated embodiment of FIG. 1, each of the partial-width wireshelves 102 is suspended from the full-width wire shelf 101 by twoS-shaped brackets 104, although it will be appreciated that thepartial-width wire shelves 102 may be suspended by any other suitablenumber of S-shaped brackets 104, such as between one and four or more.

With continued reference to FIG. 2B, end 130 of each of the outermostlongitudinal rods 128 includes a downwardly turned prong 140. Thedownwardly turned prongs 127 are configured to detachably engage thekeyhole-shaped openings 116 in the side legs 115 of the vertical supportposts 114, 115 to detachably couple the one end 130 of the partial-widthwire shelf 101 to the storage rack 100, as illustrated in FIG. 1. In theillustrated embodiment, the opposite end 131 of each of the outermostlongitudinal rods 128 is not provided with a downwardly turned prong 140because end 131 of the partial-width wire shelf 102 is suspended fromthe full-width wire shelf 101 by at least one S-shaped bracket 104, asillustrated in FIG. 1. Although in the illustrated embodiments, theS-shaped brackets 104 suspending the partial-width wire shelves 102 aredetachably coupled to the full-width wire shelf 101, in an alternateembodiment, the S-shaped brackets 104 may be detachably coupled to oneof the crossbeams 107, 108 of the storage rack 100.

With reference now to FIG. 2C, the partial-width wire shelf 103 includesa plurality of interconnected longitudinal rods 132 and transverse rods133. Together, the longitudinal and transverse rods 132, 133,respectively, define a mesh wire shelf 103 configured to support variousarticles, such as tools and other equipment commonly stored in a garage.Unlike the full-width wire shelf 101 and the partial-width wire shelf102 described above, both ends 134, 135 of the partial-width wire shelf103 are configured to be suspended from the full-width wire shelf 101 byat least one S-shaped bracket 104. In the illustrated embodiment of FIG.1, each partial-width wire shelf 103 is suspended from the full-widthwire shelf 101 by four S-shaped brackets 104 (i.e., each corner of thepartial-width wire shelf 103 is suspended from the full-width wire shelf101 by one S-shaped bracket 104). It will be appreciated, however, thatthe partial-width wire shelves 103 may be suspended by another othersuitable number of S-shaped brackets 104, such as between two and eightor more. Additionally, although in the illustrated embodiments, theS-shaped brackets 104 suspending the partial-width wire shelves 103 aredetachably coupled to the full-width wire shelf 101, in an alternateembodiment, the S-shaped brackets 104 may be detachably coupled to thecrossbeams 107, 108 of the storage rack 100.

With reference now to the embodiment illustrated in FIG. 3, the S-shapedbrackets 104 each include a vertical segment 136, a downwardly turnedhook portion 137 on an upper end of the vertical segment 136 and anupwardly turned hook portion 138 on a lower end of the vertical segment136. The downwardly turned hook portion 137 of the S-shaped brackets 104is configured to be detachably coupled to either the longitudinal rods125 on the full-width wire shelf 101 or the crossbeams 107, 108. Theupwardly turned hook portion 138 of the S-shaped brackets 104 isconfigured to be detachably coupled to the longitudinal rods 128, 132 ofthe partial-width wire shelves 102, 103. It will be appreciated that thelength of the vertical segment 136 of the S-shaped bracket 104 may beselected to achieve the desired spacing between the full-width wireshelf 101 and the partial-width wire shelves 102, 103 suspended from thefull-width wire shelf 101.

While this invention has been described in detail with particularreferences to exemplary embodiments thereof, the exemplary embodimentsdescribed herein are not intended to be exhaustive or to limit the scopeof the invention to the exact forms disclosed. Persons skilled in theart and technology to which this invention pertains will appreciate thatalterations and changes in the described structures and methods ofassembly and operation can be practiced without meaningfully departingfrom the principles, spirit, and scope of this invention, as set forthin the following claims. Although relative terms such as “outer,”“inner,” “upper,” “lower,” “below,” “above,” “vertical, “horizontal” andsimilar terms have been used herein to describe a spatial relationshipof one element to another, it is understood that these terms areintended to encompass different orientations of the various elements andcomponents of the device in addition to the orientation depicted in thefigures.

As used herein, and unless the context dictates otherwise, the term“coupled to” is intended to include both direct coupling (in which twoelements that are coupled to each other contact each other) and indirectcoupling (in which at least one additional element is located betweenthe two elements). Therefore, the terms “coupled to” and “coupled with”are used synonymously.

As used in the description herein and throughout the claims that follow,the meaning of “a,” “an,” and “the” includes plural reference unless thecontext clearly dictates otherwise. Also, as used in the descriptionherein, the meaning of “in” includes “in” and “on” unless the contextclearly dictates otherwise.

The recitation of ranges of values herein is merely intended to serve asa shorthand method of referring individually to each separate valuefalling within the range. Unless otherwise indicated herein, eachindividual value is incorporated into the specification as if it wereindividually recited herein. All methods described herein can beperformed in any suitable order unless otherwise indicated herein orotherwise clearly contradicted by context. The use of any and allexamples, or exemplary language (e.g. “such as”) provided with respectto certain embodiments herein is intended merely to better illuminatethe invention and does not pose a limitation on the scope of theinvention otherwise claimed. No language in the specification should beconstrued as indicating any non-claimed element essential to thepractice of the invention.

Groupings of alternative elements or embodiments of the inventiondisclosed herein are not to be construed as limitations. Each groupmember can be referred to and claimed individually or in any combinationwith other members of the group or other elements found herein. One ormore members of a group can be included in, or deleted from, a group forreasons of convenience and/or patentability. When any such inclusion ordeletion occurs, the specification is herein deemed to contain the groupas modified thus fulfilling the written description of all Markushgroups used in the appended claims

It should be apparent to those skilled in the art that many moremodifications besides those already described are possible withoutdeparting from the inventive concepts herein. The inventive subjectmatter, therefore, is not to be restricted except in the spirit of theappended claims. Moreover, in interpreting both the specification andthe claims, all terms should be interpreted in the broadest possiblemanner consistent with the context. In particular, the terms “comprises”and “comprising” should be interpreted as referring to elements,components, or steps in a non-exclusive manner, indicating that thereferenced elements, components, or steps may be present, or utilized,or combined with other elements, components, or steps that are notexpressly referenced. Where the specification claims refers to at leastone of something selected from the group consisting of A, B, C . . . andN, the text should be interpreted as requiring only one element from thegroup, not A plus N, or B plus N, etc.

What is claimed is:
 1. A system configured to convert a space between afirst shelf panel and a second shelf panel on a storage rack into usablestorage space, the storage rack comprising a first vertical supportmember and a second vertical support member, and wherein the storagerack has a width defined by the distance between the first verticalmember and the second vertical member, the system comprising: afull-width wire rack comprising (i) a plurality of longitudinal rods,(ii) at least one transverse rod interconnected with at least one of theplurality of longitudinal rod, and (iii) a downwardly turned prongconfigured to detachably engage a of keyhole-shaped opening in at leastone of the first and second vertical support members to detachablyconnect the full-width wire rack to the storage rack; and apartial-width wire rack suspended from the full-width wire rack by atleast one S-shaped bracket.
 2. The system of claim 1, further comprisinga crossbeam boltlessly coupled to the first vertical support member anda second vertical support member.
 3. The system of claim 2, wherein thecrossbeam has a generally omega-shaped transverse cross-section.
 4. Thesystem of claim 1, wherein the full-width wire rack is repositionablealong the first and second vertical supports.
 5. The system of claim 1,wherein the partial-width wire rack has a first end and a second end,and wherein the first end is suspended from the full-width wire rack byat least one S-shaped bracket, and the second end of the partial-widthwire rack is detachably connected to at least one of the first andsecond vertical support members of the storage rack.
 6. The system ofclaim 5, wherein the partial-width wire rack has at least one downwardlyturned prong configured to detachably engage a plurality ofkeyhole-shaped openings in at least one of the first and second verticalsupport members to detachably connect the partial-width rack to thestorage rack.
 7. The system of claim 1, wherein the S-shaped bracketcomprises a vertical segment, a first end, and a second end, wherein thefirst end comprises a first downwardly turned hook portion and thesecond end comprises an upwardly turned hook portion.
 8. The system ofclaim 7, wherein the downwardly turned hook portion is configured to bedetachably coupled to at least one of the longitudinal rods on thefull-width wire shelf.
 9. The system of claim 7, wherein the upwardlyturned hook portion is configured to be detachably coupled to thelongitudinal rods of the partial-width wire shelf
 10. The system ofclaim 7, wherein the downwardly turned hook portion and the upwardlyturned hook portion are configured to face oppositely.
 11. The system ofclaim 7, wherein the downwardly turned hook portion and the upwardlyturned hook portion has a same dimension.
 12. A system configured toconvert a space between a first shelf panel and a second shelf panel ona storage rack into usable storage space, wherein the storage rackcomprises: (a) first and second vertical support members each having aplurality of key-hole shaped openings; (b) a first wire rack having (i)a plurality of longitudinal rods, (ii) at least one transverse rodinterconnected with at least some of the plurality of longitudinal rods,and (iii) at least one downwardly turned prong configured to detachablyengage at least one of the plurality of keyhole-shaped openings in thevertical support member to detachably connect the wire rack to thestorage rack; and (c) a width defined by the distance between the firstand second vertical support members, the system comprising: a secondwire rack having a plurality of interconnected longitudinal rods andtransverse rods and at least one downwardly turned prong; and at leastone S-shaped bracket having a first S-shaped end and a second S-shapedend, sized and dimensioned to hook at least one of the longitudinal rodsand transverse rods.
 13. The system of claim 13, wherein the first wirerack is a full-width wire rack
 14. The system of claim 13, wherein thesecond wire rack is a partial-width wire rack.